Yamaha YFM660 01 User Manual

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CHK
ADJ
CHECKING THE BATTERY
Charging method using a constant voltage charger 
						

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CHK
ADJ
CHECKING THE BATTERY/CHECKING THE FUSE
5.Check:

Battery terminals
Dirty →
 Clean with a wire brush.
Poor connection →
 Correct.
NOTE:
After cleaning the terminals, apply a light coat
of grease.
6.Install:

Battery
7.Connect:

Battery leads
CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.
8.Install:

Battery holding bracket

Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
CHECKING THE FUSE
CAUTION:
Always turn off the main switch when
checking or replacing a fuse. Otherwise, a
short circuit may occur.
1.Remove:

Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Check:

Fuse
***********************************************
Checking steps:

Connect the pocket tester to the fuse and
check it for continuity. 
						

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CHK
ADJ
CHECKING THE FUSE
NOTE:
Set the tester to the “Ω
 ×
 1” position.

If the tester indicates 0, replace the fuse.
***********************************************
Pocket tester:
P/N. YU-03112, 90890-03112
3.Replace:

Blown fuse
***********************************************
Replacement steps:

Turn off the ignition.

Install a new fuse of the proper amperage.

Turn on switches to verify operation of the
related electrical devices.

If the fuse immediately blows again, check
the electrical circuit.
***********************************************
WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may
cause extensive damage to the electrical
system, a malfunction of the lighting and
ignition systems and could possibly cause
a fire.
4.Install:

Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.Description Current rating Quantity
Main 20 A 1
Reserve 20 A 1 
						

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CHK
ADJADJUSTING THE HEADLIGHT BEAM/
REPLACING THE HEADLIGHT BULB
ADJUSTING THE HEADLIGHT BEAM
1.Adjust:

Headlight beam (vertically) 
***********************************************
Adjustment steps:

Loosen the screw 1
.

Slide the headlight lens unit under.

Tighten the screw 1
.
***********************************************
Slide forward Headlight beam raises.
Slide backwardHeadlight beam low-
ers.
REPLACING THE HEADLIGHT BULB
1.Remove:

Headlight
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Remove:

Cover 1
 

Headlight unit 2
 

Case 3
 
NOTE:
Pull outward on the rear of the headlight unit
2
, and then pull out ward on the front. 
						

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CHK
ADJ
REPLACING THE HEADLIGHT BULB
3.Remove:

Cover 1
 

Bulb holder 2
 

Bulb
NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
Keep flammable products and your hands
away from the bulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.
4.Install:

Bulb 
Secure the new bulb with the headlight unit.
CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the trans-
parency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lac-
quer thinner.
5.Install:

Bulb holder

Cover

Cover
6.Install:

Headlight
Refer to “SEAT, FENDERS AND FUEL
TANK”.
New 
						

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CHASFRONT WHEELS
CHASSIS
FRONT WHEELS
FRONT WHEELS
Order Job name/Part name Q’ty Remarks
Removing the front wheel
Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.
1 Cotter pin 1
Refer to “INSTALLING THE WHEEL 
HUB”.
2 Axle nut 1
3 Front wheel 1 Refer to “INSTALLING THE WHEEL”.
4 Brake disc guard (outer) 1
5 Brake caliper assembly 1
NOTE:
Do not apply the brake lever after the
brake calipers have been removed, other-
wise the brake pads will be forced shut. 
						

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CHASFRONT WHEELS
Order Job name/Part name Q’ty Remarks
6 Wheel hub 1
7 Brake disc 1
For installation, reverse the removal pro-
cedure. 
						

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CHASFRONT WHEELS
CHECKING THE WHEEL
1.Check:

Wheel
2.Measure:

Wheel runout
Over the specified limit →
 Replace the wheel 
or check the wheel bearing play 1
.
3.Check:

Wheel balance
Out of balance →
 Adjust.
Wheel runout limit:
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in machine damage and possible
operator injury.
CHECKING THE WHEEL HUB
1.Check:

Wheel hub 1
 
Cracks/damage →
 Replace.  
						

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CHASFRONT WHEELS
2.Check:

Wheel bearings 
Wheel hub play/wheel turns roughly →
 
Replace. 
***********************************************
Wheel bearing replacement steps:

Clean wheel hub exterior.

Drive bearing out by pushing spacer aside
and tapping around perimeter of bearing
inner race. Use soft metal drift punch and
hammer. The spacer 1
 “floats” between
bearings. Remove both bearings as
described.
WARNING
Eye protection is recommended when
using striking tools.

To install the wheel bearings, reverse the
above sequence. Use a socket that matches
outside diameter of bearing outer race to
drive in bearing.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
***********************************************
CHECKING THE BRAKE DISC
1.Check:

Brake disc
Galling/damage →
 Replace.
2.Measure:

Brake disc deflection
Out of specification →
 Replace.

Brake disc thickness a
Out of specification →
 Replace.
Brake disc maximum deflection:
0.15 mm (0.006 in)
Brake disc minimum thickness:
3 mm (0.12 in) 
						

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CHASFRONT WHEELS
INSTALLING WHEEL HUB
1.Install:

Axle nut 1
 

Cotter pin 2
NOTE:
Do not loosen the axle nut after torquing it. If
the axle nut groove is not aligned with the cot-
ter pin hole, align the groove with the hole by
tightening the axle nut.
T R..70 Nm (7.0 m  kg, 50 ft  lb)
New
INSTALLING THE WHEEL
1.Install:

Brake disc guard (outer) 1
 
NOTE:
Install the brake disc guard (outer) with
punched burrs 2
 on the wheel hub side.
2.Install:

Wheel
NOTE:
The arrow mark 1
 on the tire must point in the
direction of rotation È
 of the wheel.